publication . Bachelor thesis . 2017

Electrical connection for aluminium conductors in automotive applications : Prestudy of available solutions for electrical connection methods of aluminium cables

Hamedi, Emilia;
Open Access English
  • Published: 01 Jan 2017
  • Publisher: KTH, Materialvetenskap
  • Country: Sweden
Abstract
Due to increasing weight of electrical component and wiring harnesses in a vehicle contrary to the demand of light constructed vehicles as well as the constantly increasing and fluctuating price of copper compared to aluminium’s stable and far lower price, the use of aluminium conductors as an alternative have been promoted.  This thesis work lay theoretical research of the available methods used for electrical connection of aluminium conductors in order to increase the knowledge about the available termination techniques.  Due to aluminium’s characteristics such as lower conductivity and strength, tendency to form oxides and relax over time, differences in ther...
Subjects
free text keywords: Connector, electrical contact, termination, aluminium conductor, Materials Engineering, Materialteknik
Related Organizations
Download from

Transmission, power grid, lines (1350)

[4] K. Oba, “Wiring harnesses for Next Generation Automobiles,” Fujikora, Tokyo, 2013.

[36] Y. Yamano, T. Hosokawa, H. Hirai, J. Ono, T. Otsuka, M. Tabata, Y. Otsuka, T. Nishikawa, S. Kitamura and J. Yoshimoto, “Development of Aluminum Wiring Harness,” SEI TECHNICAL REVIEW, no. 73, pp. 73-79, 10 2011.

[37] T. Otsuka, H. Hirai and J. Ono, “Crimping Technology of Aluminum Wire for Automotive Wire Harness,” SAE International, Tokyo, Japan, 2012.

[38] J. Gimholt, P. Li, L. Orbeus and J. Björk, Electrical connections in vehicles - Requirements and testing, Södertälje: Scania, 2016.

[39] J. R. Davis, ASM Handbook Volume 6: Welding, Brazing and Soldering, D. L. Olsson, Ed., ASM International, 1993, p. 164.

[40] G. J. Witter and G. Horn, “Contact Design and Attachment,” in Electrical Contacts Principles and Applications, 2 ed., P. G. Slade, Ed., CRC Press, 2013, pp. 960-966.

[41] M. Bloss and K. Graff, “http://www.thefabricator.com/article/arcwelding/understandingultrasonic-welding,” 09 2008. [Online]. Available: http://www.thefabricator.com. [Accessed 23 02 2017].

[42] How A Wiring Harness Splice is Ultrasonically Welded. [Film]. USA: Lectric Limited , 2013.

[67] K. Yasuda, S. Umemura and T. Aoki, “Degradation Mechanisms in Tin- and Gold-Plated Connector Contacts,” IEEE Transactions on Components, Hybrids, and Manufacturing Technology , vol. 10, no. 3, pp. 456-462, 9 1987.

Abstract
Due to increasing weight of electrical component and wiring harnesses in a vehicle contrary to the demand of light constructed vehicles as well as the constantly increasing and fluctuating price of copper compared to aluminium’s stable and far lower price, the use of aluminium conductors as an alternative have been promoted.  This thesis work lay theoretical research of the available methods used for electrical connection of aluminium conductors in order to increase the knowledge about the available termination techniques.  Due to aluminium’s characteristics such as lower conductivity and strength, tendency to form oxides and relax over time, differences in ther...
Subjects
free text keywords: Connector, electrical contact, termination, aluminium conductor, Materials Engineering, Materialteknik
Related Organizations
Download from

Transmission, power grid, lines (1350)

[4] K. Oba, “Wiring harnesses for Next Generation Automobiles,” Fujikora, Tokyo, 2013.

[36] Y. Yamano, T. Hosokawa, H. Hirai, J. Ono, T. Otsuka, M. Tabata, Y. Otsuka, T. Nishikawa, S. Kitamura and J. Yoshimoto, “Development of Aluminum Wiring Harness,” SEI TECHNICAL REVIEW, no. 73, pp. 73-79, 10 2011.

[37] T. Otsuka, H. Hirai and J. Ono, “Crimping Technology of Aluminum Wire for Automotive Wire Harness,” SAE International, Tokyo, Japan, 2012.

[38] J. Gimholt, P. Li, L. Orbeus and J. Björk, Electrical connections in vehicles - Requirements and testing, Södertälje: Scania, 2016.

[39] J. R. Davis, ASM Handbook Volume 6: Welding, Brazing and Soldering, D. L. Olsson, Ed., ASM International, 1993, p. 164.

[40] G. J. Witter and G. Horn, “Contact Design and Attachment,” in Electrical Contacts Principles and Applications, 2 ed., P. G. Slade, Ed., CRC Press, 2013, pp. 960-966.

[41] M. Bloss and K. Graff, “http://www.thefabricator.com/article/arcwelding/understandingultrasonic-welding,” 09 2008. [Online]. Available: http://www.thefabricator.com. [Accessed 23 02 2017].

[42] How A Wiring Harness Splice is Ultrasonically Welded. [Film]. USA: Lectric Limited , 2013.

[67] K. Yasuda, S. Umemura and T. Aoki, “Degradation Mechanisms in Tin- and Gold-Plated Connector Contacts,” IEEE Transactions on Components, Hybrids, and Manufacturing Technology , vol. 10, no. 3, pp. 456-462, 9 1987.

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